Hpc and hpt disks coated by atomic layer deposition

Abstract

A process for coating a gas turbine engine disk comprises placing the disk having an outer surface into a chamber, the chamber configured to perform atomic layer deposition; injecting a first reactant into the chamber; forming a first monolayer gas thin film on the outer surface; removing the first reactant from the chamber; injecting a second reactant into the chamber; reacting second reactant with the first monolayer gas thin film; removing the second reactant from the chamber; and forming a protective barrier coating on the outer surface.

1 - 16 . (canceled) 
     
     
         17 . A process for coating a gas turbine engine component comprising:
 placing said component having an alloy substrate having an outer surface into a chamber, said chamber configured to perform atomic layer deposition;   injecting a first reactant into said chamber, so as to form a first monolayer gas thin film directly on said component;   removing said first reactant from said chamber;   injecting a second reactant into said chamber, so as to react with said first monolayer gas thin film to form a first monolayer solid thin film on said outer surface;   removing said second reactant from said chamber; and   forming a single oxide phase protective barrier coating directly on said component; wherein said first monolayer gas thin film and a second monolayer solid thin film comprise a total thickness of from 0.1 micron to 10 microns.   
     
     
         18 . The process of  claim 17 , further comprising:
 determining a thickness of said protective barrier coating; and   repeating the steps of injecting and removing said first reactant and repeating the step of injecting and removing said second reactant responsive to determining said thickness of said protective barrier coating.   
     
     
         19 . The process of  claim 17 , further comprising:
 prior to injecting said first reactant into said chamber, creating a vacuum in said chamber; and   heating said chamber to a predetermined temperature.   
     
     
         20 . The process of  claim 19 , wherein said predetermined temperature enables said step of forming a first monolayer gas thin film on internal surfaces and said step of injecting said second reactant to form said monolayer solid thin film. 
     
     
         21 . The process of  claim 17 , wherein said first reactant comprises an oxide precursor and said second reactant comprises an oxidant. 
     
     
         22 . The process of  claim 17 , wherein said first monolayer solid thin film and said second monolayer solid thin film form a protective barrier coating comprising Cr 2 O 3 . 
     
     
         23 . The process of  claim 17 , wherein said first monolayer gas thin film and said second reactant form said protective barrier coating comprising a material selected from the group consisting of Al 2 O 3 . 
     
     
         24 . The process of  claim 17 , wherein said gas turbine engine component is selected from the group consisting of a high pressure compressor component and a high pressure turbine component. 
     
     
         25 . A gas turbine engine component comprising:
 a protective barrier coating formed directly on the component by the process of  claim 17 .   
     
     
         26 . The gas turbine engine component according to  claim 25 , wherein said protective barrier coating comprises Cr 2 O 3 . 
     
     
         27 . The gas turbine engine component according to  claim 25 , wherein said protective barrier coating is a material selected from the group consisting of Al 2 O 3 . 
     
     
         28 . The gas turbine engine component according to  claim 25 , wherein said protective barrier coating has a thickness configured to minimize a fatigue debit of the component.